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"Basic Gas Turbine Metallurgy and Repair Technology Workshop"
Pre-Conference IGTI Workshop being held in conjunction with Turbo Expo 2012
Sunday, June 10, 2012
Bella Convention & Exhibition Center
Copenhagen, Denmark
Overview and Objective
This workshop will explain super-alloy materials, component damage experienced from service exposure, techniques used to analyze the remaining life of components removed from service, protective coatings, component repair technologies, and quality assurance of repairs. The workshop includes many case study examples and the last section is devoted to a workshop where attendees develop component repair solutions. Participants may submit questions in
advance regarding repair issues faced in their jobs. Earn 7 Professional Development Hours (PDH's) and receive a certificate of completion!
After completing the course the participants should be able to explain ...
- what makes superalloys especially suited for gas turbine components
- how different damage mechanisms (oxidation, corrosion, erosion) affect
the component
- how high cycle fatigue & low cycle fatigue damage is caused, prevented,
and repaired
- when various heat treatments are used in repairs, and why they are important
- advantages & disadvantages of the many types of protective coatings
- critical quality control steps in component repair
- how to reliably extend the service life of valuable components
Who Should Attend
A “must” for gas turbine maintenance engineers, managers, repair
shop personnel, designers, and technical staff to optimize their repair
planning and performance. Useful for business and plant managers, investors
and insurers to understand the technology and support sound decision-making.
| Course Schedule: |
Sunday, June 10, 2012
8:30 a.m. to 5:00 p.m. |
Section I |
Introduction: Why repair and refurbish parts?
- Repair Market Trends
- Cost Benefit of Repairs
- Industry Trends
- The Future for Industrial Frame GT Repairs
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| Section II |
Gas Turbine Nomenclature, Operations and
Maintenance Planning
- Industrial Gas Turbine Nomenclature Industrial and Aero-derivative
- Typical Gas Turbine Component Materials
- Design Differences
- Advanced Design Turbine Blade Data
- Operating Modes – Industrial Engines – Industrial
Frame Engines
- Inspection and Maintenance Intervals
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| Section III |
Materials and Metallurgy: Gas Turbine Materials
and their Properties
- Overview of Why Superalloys are Used in a Gas Turbine
- Overview of Superalloy Production Routes
- Investment (Lost Wax) Casting
- Processing and manufacture of materials
- Superalloys Compositions and Properties
- Solid Solution Strengthening
- Precipitation Strengthening
- Grain boundary Strengthening
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| 10:00 a.m. – 10:15 a.m. |
Coffee Break |
| Section IV |
Gas Turbine Coatings
- The Role Of Engineering Coatings
- Applications
- Selection of Coatings
- Coating Microstructure and Performance
- Coating methods
- Slurries and Paints
- Pack Process
- Chemical Vapor Deposition
- Thermal Spraying
- Physical Vapor Deposition
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Section V
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Degradation Characteristics in Gas Turbine
Components
- Mechanical and Metallurgical Effects of Service
- Creep – High Cycle Fatigue – Low Cycle Fatigue
- Environmental Attack –Oxidation –Corrosion
- Coating Degradation, Depletion, Cracking, TBC's
- Thermal Mechanical Fatigue (TMF) Damage
- Microstructural aging and evolution
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| 12:00 a.m. – 1:00 p..m. |
Group Lunch |
Section VI
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Component Evaluation
- Component evaluation - where, how and why
- Component Management Program
- Timing and selection of components for analysis
- Micro structural analysis
- Mechanical testing
- Coating Evaluation
- Failure Analysis
- Root Cause of Damage, and Corrective/Preventive Action
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| Section VII |
Refurbishment & Repair Processes: Procedures
and techniques used to restore
components to industry standards
- Typical Damage
- Coating Removal
- Dimensional Checks
- Re-Coating Selection and Processes
- HIP and Rejuvenation Heat Treatments
- Superalloy Weld Process
- Diffusion Brazing
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| 3:15 p.m. – 3:30 p.m. |
Coffee Break |
| Section VIII |
Quality Assurance and Inspection Methods
- QA Certification, Inspections and Quality Plan
- NDE Defect Criteria
- Dimensional Specification
- NDE Inspection techniques
- Repair Shop Selection and Qualifications
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| Section IX |
Case Studies & Problem Solving
- Case Studies of Turbine component damage and repair strategies
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| 5:00 p.m. |
Wrap-up and Evaluation |
| Instructors
Lloyd Cooke
P. Eng., Liburdi Engineering Ltd Lloyd graduated from the University
of Windsor with a degree in Mechanical Engineering. After graduation he worked as a design engineer for turbine components at Magellan Aerospace and then joined TransCanada Pipelines where he held various engineering and senior management positions responsible for gas turbine installation, maintenance, and support. In 1990 he joined Liburdi Engineering as Director, Operations where he is responsible for gas turbine services including component repair, engine upgrade and engineering analysis. Lloyd has been involved with gas turbine engines for over 30 years and has the special perspective of having worked as an OEM component designer, an Operation & Maintenance Sr. Fleet Manager, and as Technical Director for repair and overhaul support services. He has published several technical papers and is a committee member of the ASME and IAGT.
Doug Nagy
P. Eng., Liburdi Engineering Ltd Doug is a Senior Metallurgical Engineer at Liburdi Engineering. Doug received a B.Eng. in Ceramic Engineering in 1986 from McMaster University in Hamilton. Doug is responsible for repairs servicing the heavy duty industrial market. He has extensive experience in the analysis of various industrial and aero gas turbine components and development of coatings and repair processes. He is co-author of 22 technical publications dealing with coating design and application as well as repair of gas turbine components.
Warren Miglietti
Ph.D. Materials Eng. Power Systems Manufacturing Ltd. (PSM)-An Alstom Company. Dr. Warren Miglietti, is a Technical Expert in the Reconditioning dept. at PSM. His principal responsibility is the development of novel repair techniques and processes for components, operating in advanced land based gas turbine engines, such as the Frame 7FA+e and W501F engines. He has 23 years of experience and expertise in the welding, brazing, acid stripping and heat treatment of Nickel and Cobalt base superalloys, as well as Titanium, Aluminum and Stainless Steels. Since University graduation Warren's career has
focused on developing repair techniques and processes for turbomachinery components for industrial, aircraft and aero-derivative components. Warren continues to support the industry as chairman of the Commission XVII committee – "Brazing, Soldering and Diffusion Bonding" of the International Institute of Welding (IIW). He has supported the Manufacturing, Materials and Metallurgy (MMM) committee activities of the ASME/IGTI for 23 consecutive years. He has also authored or co-authored the publication of 42 technical papers and has 2 repair technology patents granted and has 7 repair technology patents pending.
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